Kraftpowercon Pcm2 User manual

KraftPowercon Sweden AB, Hjalmar Petris väg 49, S-352 46 Växjö, Sweden, Tel: +46 470-705200, Fax: +46 470-705201,

www.kraftpowercon.com

You must read this manual before installation, use or work on the product.

This product contains dangerous voltage that when touched can cause electric shock, burns or

death.

The product must be installed by qualified personnel and according to the installation instructions.

Service may only be performed by authorised service personnel. The equipment housing may only

be removed by authorised personnel when all power has been cut to the equipment for at least

five minutes. The protective covers and contact safety devices inside the equipment may only be

removed by authorised service personnel.

The power must always be disconnected in a safe way before starting any service/maintenance.

Manual for

Monitoring unit type PCM2

SAFETY INSTRUCTIONS

Manual: 9-1623-C

P/n: 0001077

KraftPowercon Sweden AB, Hjalmar Petris väg 49, S-352 46 Växjö, Sweden, Tel: +46 470-705200, Fax: +46 470-705201,

www.kraftpowercon.com

We reserve the right to make changes to the content of this manual without prior notification.

KraftPowercon Sweden AB, Hjalmar Petris väg 49, S-352 46 Växjö, Sweden, Tel: +46 470-705200, Fax: +46 470-705201,

www.kraftpowercon.com

CONTENTS

1PRESENTATION...................................................................................... 7

2SAFETY INSTRUCTIONS......................................................................... 8

3TECHNICAL DATA ................................................................................. 9

3.1ELECTRICAL DATA ...................................................................................................................... 9

3.1.1Common electrical data........................................................................................................... 9

3.1.2Model dependent electrical data.............................................................................................. 9

3.2Environmental data ...................................................................................................................... 9

3.3Mechanical data .......................................................................................................................... 9

3.3.1Operator panel ........................................................................................................................ 9

3.3.2I/O module ............................................................................................................................ 10

3.4Conformity with standards ......................................................................................................... 10

4FUNCTIONAL DESCRIPTION................................................................11

4.1GENERAL................................................................................................................................... 11

4.2OPERATOR PANEL.................................................................................................................... 11

4.3I/O UNIT.................................................................................................................................... 11

4.4FUNCTIONS.............................................................................................................................. 11

4.4.1Float charging ........................................................................................................................ 11

4.4.2Equalizing charging ............................................................................................................... 12

4.4.2.1General ............................................................................................................................. 12

4.4.2.2Manual equalizing charging .............................................................................................. 12

4.4.2.3Automatic equalizing charging.......................................................................................... 12

4.4.3Battery circuit test .................................................................................................................. 12

4.4.3.1Simple battery circuit test .................................................................................................. 12

4.4.3.2Advanced battery circuit test ............................................................................................. 13

4.4.4Double systems...................................................................................................................... 13

4.4.4.1General ............................................................................................................................. 13

4.4.4.2Earth fault measuring......................................................................................................... 13

4.4.4.3Battery circuit test.............................................................................................................. 13

4.4.4.4Load sharing...................................................................................................................... 13

4.4.4.5System setup...................................................................................................................... 13

5OPERATION ..........................................................................................15

5.1General...................................................................................................................................... 15

5.2OPERATOR PANEL.................................................................................................................... 15

5.2.1Display .................................................................................................................................. 15

5.2.2Push buttons .......................................................................................................................... 15

5.2.3LED “Alarm” .......................................................................................................................... 16

5.3MENU MANAGEMENT............................................................................................................. 16

5.3.1General.................................................................................................................................. 16

5.3.2Select menu option................................................................................................................ 16

5.3.3Take action ............................................................................................................................ 16

5.3.4Adjust value........................................................................................................................... 16

5.4MENU OVERVIEW .................................................................................................................... 17

5.5INITIAL SCREEN ........................................................................................................................ 19

5.5.1General.................................................................................................................................. 19

5.5.2Normal float charging condition............................................................................................ 19

5.5.3Other charging conditions ..................................................................................................... 19

5.5.4Alarm..................................................................................................................................... 19

5.5.5Set clock ................................................................................................................................ 19

5.6MAIN MENU ............................................................................................................................. 20

5.7SHOW ....................................................................................................................................... 20

5.7.1General.................................................................................................................................. 20

5.7.2Show battery related data ...................................................................................................... 20

KraftPowercon Sweden AB, Hjalmar Petris väg 49, S-352 46 Växjö, Sweden, Tel: +46 470-705200, Fax: +46 470-705201,

www.kraftpowercon.com

5.7.3Show rectifier......................................................................................................................... 20

5.7.3.1Show voltage and current.................................................................................................. 20

5.7.3.2Show detailed rectifier data ............................................................................................... 20

5.7.4Show insulation ..................................................................................................................... 21

5.7.5Show statistics........................................................................................................................ 21

5.7.5.1Menu option...................................................................................................................... 21

5.7.5.2Mains fault ........................................................................................................................ 21

5.7.5.3External fault ..................................................................................................................... 21

5.7.5.4Operating time .................................................................................................................. 21

5.7.5.5Program version ................................................................................................................ 21

5.8CHARGE CONTROL.................................................................................................................. 22

5.8.1General.................................................................................................................................. 22

5.8.2Start/stop equalizing charging ................................................................................................ 22

5.8.3Manual battery circuit test ..................................................................................................... 22

5.9ALARM ...................................................................................................................................... 22

5.9.1General.................................................................................................................................. 22

5.9.2Alarm settings ........................................................................................................................ 22

5.9.2.1Level ................................................................................................................................. 23

5.9.2.2Delay ................................................................................................................................ 23

5.9.2.3Relay (A-D)........................................................................................................................ 23

5.9.2.4Relay (E-H) ........................................................................................................................ 23

5.9.2.5Return ............................................................................................................................... 23

5.9.2.6Show ................................................................................................................................. 24

5.9.3Alarm log............................................................................................................................... 24

5.9.4Rectifier status log.................................................................................................................. 24

5.10SETTINGS .................................................................................................................................. 24

5.10.1General.................................................................................................................................. 24

5.10.2Adjust the voltage level for float charging .............................................................................. 24

5.10.3Adjust the voltage level for equalizing charging..................................................................... 24

5.10.4Adjust the current limit value................................................................................................. 25

5.10.5Adjust clock........................................................................................................................... 25

5.11ADVANCED .............................................................................................................................. 25

5.12TEST & CALIBRATE.................................................................................................................... 25

5.12.1General.................................................................................................................................. 25

5.12.2Show status for digital inputs ................................................................................................. 25

5.12.3Test digital outputs................................................................................................................. 26

5.12.3.1Test alarm outputs A-D ................................................................................................. 26

5.12.3.2Test alarm outputs E-H .................................................................................................. 26

5.12.3.3Test other outputs.......................................................................................................... 26

5.12.4Calibrate measuring of battery voltage................................................................................... 26

5.12.5Calibrate measurement of mid voltage................................................................................... 27

5.12.6Lamp test ............................................................................................................................... 27

5.13FUNCTIONS.............................................................................................................................. 27

5.13.1General.................................................................................................................................. 27

5.13.2Select language...................................................................................................................... 27

5.13.3Parameters for mid voltage measurement .............................................................................. 27

5.13.4Parameters for measuring battery temperature ....................................................................... 28

5.13.5Parameters for battery circuit test ........................................................................................... 29

5.13.6Parameters for equalizing charging........................................................................................ 29

5.13.7Lowest possible voltage level, Uminimum............................................................................. 30

5.13.8Highest possible voltage level, Umaximum (HVSD) .............................................................. 30

5.13.9Parameters for RI compensation............................................................................................. 30

5.13.10Parameters for external alarm ............................................................................................ 30

5.13.11Special functions ............................................................................................................... 31

5.13.12Other functions ................................................................................................................. 31

5.14SYSTEM DATA........................................................................................................................... 31

5.14.1General.................................................................................................................................. 31

5.14.2Specify rated voltage.............................................................................................................. 31

KraftPowercon Sweden AB, Hjalmar Petris väg 49, S-352 46 Växjö, Sweden, Tel: +46 470-705200, Fax: +46 470-705201,

www.kraftpowercon.com

5.14.3Specify rated current.............................................................................................................. 31

5.14.4Specify number of rectifiers ................................................................................................... 32

5.14.5Specify system affiliation........................................................................................................ 32

5.15SERVICE..................................................................................................................................... 32

5.16ALARM MESSAGES.................................................................................................................... 32

5.16.1General.................................................................................................................................. 32

5.16.2Alarm during delay ................................................................................................................ 33

5.16.3Active alarm .......................................................................................................................... 33

5.16.4Inactive alarm ........................................................................................................................ 33

5.16.5Alarm queue.......................................................................................................................... 33

5.16.6Alarm descriptions................................................................................................................. 34

6INSTALLATION INSTRUCTIONS...........................................................39

6.1SAFETY INSTRUCTIONS............................................................................................................ 39

6.2UNITS AND CONNECTIONS ................................................................................................... 39

6.3OPERATOR PANEL.................................................................................................................... 39

6.3.1Ordinary operator panel ........................................................................................................ 39

6.3.2Satellite panel (option) ........................................................................................................... 40

6.4I/O UNIT.................................................................................................................................... 40

6.4.1General.................................................................................................................................. 40

6.4.2Power supply......................................................................................................................... 40

6.4.3Measuring inputs ................................................................................................................... 40

6.4.3.1Battery voltage................................................................................................................... 40

6.4.3.2Mid voltage ....................................................................................................................... 40

6.4.3.3Earth fault measuring......................................................................................................... 41

6.4.3.4Battery temperature ........................................................................................................... 41

6.4.4Digital inputs ......................................................................................................................... 41

6.4.4.1General ............................................................................................................................. 41

6.4.4.2Blocking of equalizing charging ........................................................................................ 41

6.4.4.3Fuse monitoring................................................................................................................. 41

6.4.4.4Blocking of earth fault measuring/battery test .................................................................... 42

6.4.4.5External faults .................................................................................................................... 42

6.4.5Digital outputs ....................................................................................................................... 42

6.4.5.1General ............................................................................................................................. 42

6.4.5.2Alarm outputs.................................................................................................................... 42

6.4.5.3Fan control ........................................................................................................................ 43

6.4.5.4Battery test......................................................................................................................... 43

6.4.6Internal communications interface......................................................................................... 43

6.4.7External communications interface ........................................................................................ 43

6.4.7.1RS-232 .............................................................................................................................. 43

6.4.7.2Ethernet ............................................................................................................................. 43

6.4.7.3I2C ..................................................................................................................................... 43

6.5I/O UNIT 2 (option).................................................................................................................... 44

6.5.1General.................................................................................................................................. 44

6.5.2Power supply......................................................................................................................... 44

6.5.3Measuring inputs ................................................................................................................... 44

6.5.4Digital inputs ......................................................................................................................... 44

6.5.5Digital outputs ....................................................................................................................... 44

6.5.5.1General ............................................................................................................................. 44

6.5.5.2Alarm outputs.................................................................................................................... 44

6.5.6Internal communications interface......................................................................................... 45

6.5.7External communications interface ........................................................................................ 45

6.5.7.1RS-232 .............................................................................................................................. 45

6.5.7.2Ethernet ............................................................................................................................. 45

6.5.7.3I2C ..................................................................................................................................... 45

7COMMISSIONING ................................................................................46

7.1SAFETY INSTRUCTIONS............................................................................................................ 46

7.2ELECTRIFICATION..................................................................................................................... 46

KraftPowercon Sweden AB, Hjalmar Petris väg 49, S-352 46 Växjö, Sweden, Tel: +46 470-705200, Fax: +46 470-705201,

www.kraftpowercon.com

7.3CHECK OF SETTINGS................................................................................................................ 46

7.4CHECK OF OUTPUTS ............................................................................................................... 46

8MAINTENANCE.....................................................................................47

8.1ANNUAL INSPECTION.............................................................................................................. 47

8.1.1General.................................................................................................................................. 47

8.1.2Check of measuring instruments ............................................................................................ 47

8.1.3Check of alarm circuits .......................................................................................................... 47

8.1.4Check of clock....................................................................................................................... 47

9FAULT TRACING...................................................................................48

9.1SAFETY INSTRUCTIONS............................................................................................................ 48

9.2FAULT TRACING FOLLOWING ALARM ................................................................................... 48

9.3OTHER FAULT TRACING .......................................................................................................... 48

Appendices

A BASIC SETTINGS ALARM

B BASIC SETTINGS OTHER

C RECTIFIER STATUS WORD

C RECTIFIER RAM VARIABLES

D TYPE DIAGRAM, PCM2 IN DOUBLE SYSTEMS

KraftPowercon Sweden AB, Hjalmar Petris väg 49, S-352 46 Växjö, Sweden, Tel: +46 470-705200, Fax: +46 470-705201,

www.kraftpowercon.com

1PRESENTATION

The monitoring unit type PCM2 is designed for monitoring and control of battery based DC

systems.

A strict safety approach characterises the whole product. This is evident in things like the well-

planned alarm functions, the important control characteristics such as the temperature controlled

float charging voltage and an operator panel with graphic clear text display based on a simple

and easy to understand menu system and alarm indication with both LEDs and clear text

messages.

These instructions above all deal with all operation of the monitoring unit and are therefore

chiefly aimed at the personnel that have the day to day responsibility for running the installation,

but also to other personnel who have cause to work with the DC system.

It also contains information on installation, commissioning, service, maintenance and technical

data that is specific to the monitoring unit and is therefore aimed at the personnel who are

responsible for these areas.

The monitoring unit usually works in combination with one or more rectifiers in a complete DC

system. For the description of the rectifier and the system in general, we refer you to the general

system manual.

KraftPowercon Sweden AB, Hjalmar Petris väg 49, S-352 46 Växjö, Sweden, Tel: +46 470-705200, Fax: +46 470-705201,

www.kraftpowercon.com

2SAFETY INSTRUCTIONS

This product contains dangerous voltage that when touched can cause electric shock, burns or

death.

For safety reasons the affected personnel are classified according to the following requirements for

specific skills.

Authorised service personnel:

• Have electrical training and adequate experience to avoid the dangers that electricity can

cause.

• Are certified to meet authority requirements for the work in question.

• Have linguistic skills that ensure the content in this description cannot be misunderstood.

• Have undergone a product specific training programme for authorised service personnel

that are approved by KraftPowercon Sweden AB.

Qualified personnel:

• Have electrical training and adequate experience to avoid the dangers that electricity can

cause.

• Are certified to meet authority requirements for the work in question.

• Have linguistic skills that ensure the content in this description cannot be misunderstood.

Installation, service, maintenance and fault tracing may only be carried out by authorised

personnel and in accordance with the installation manual.

The protective covers and contact safety devices inside the equipment may only be removed by

authorised service personnel.

KraftPowercon Sweden AB, Hjalmar Petris väg 49, S-352 46 Växjö, Sweden, Tel: +46 470-705200, Fax: +46 470-705201,

www.kraftpowercon.com

3TECHNICAL DATA

3.1 ELECTRICAL DATA

3.1.1 Common electrical data

Voltage range.........................................................See “Model dependent electrical data”

Show battery voltage, deviation .............................<±0.2 % of measurement range's upper limit

Show battery voltage, measurement range .............See “Model dependent electrical data”

Show rectifier current, deviation ............................<±1 % of rated current

Show rectifier current, measurement range ............0 – 110 % of rated current

Show battery temperature, deviation......................<±2 °C

Show battery temperature, measurement range......-20 – +50 °C

Show earth fault resistance, deviation ....................<±15 %, 50 kΩ – 1 MΩ

Show earth fault resistance, measurement range ....0 – 5 MΩ

Earth fault resistance input impedance ...................>200 kΩ (24 – 220 V), >900 kΩ (440 – 500 V)

Connection, supply voltage....................................0.2 – 2.5 mm2pluggable screw terminal block

Connection, relay outputs ......................................0.2 – 2.5 mm2pluggable screw terminal block

Connection, meas. inputs voltage/earth fault..........0.2 – 2.5 mm2pluggable screw terminal block

Connection, other inputs........................................0.08 – 1.5 mm2pluggable screw terminal block

Relays for alarms + fan, contact data, max .............250 VAC, 8 A at cosø=1 (resistive)

250 VAC, 3 A at cosø=0.4

24/48 VDC, 0.86A at L/R=40 ms

125 VDC, 0.37A at L/R=40 ms

250 VDC, 0.28A at L/R=40 ms

3.1.2 Model dependent electrical data

Nominal volta

e Input volta

range

Measurement

range, voltage

Power consumption at

nom. voltage

(V) (V) (V) (W)

24 18 - 75 0 - 35.8 4.7

48 18 - 75 0 - 71.6 4.8

110/125 85 - 310 0 - 163.6 5.0

220 85 - 310 0 - 327.3 5.7

440/500 300 - 600 0 - 613.8 -

3.2 Environmental data

Class of enclosure ..................................................IP20 as per EN 60529

Cooling ..................................................................Natural convection

Ambient temperature (specified data applies).........0 to +40 °C

Ambient temp. (spec. data are not guaranteed) ......-5 to +55 °C

Storage temperature ..............................................-40 to +70 °C

Humidity ...............................................................<90 % RH, non-condensed

Altitude above sea level ........................................<2000 m

Noise level.............................................................<35 dBA

3.3 Mechanical data

3.3.1 Operator panel

Mounting .............................. For folding into panel

KraftPowercon Sweden AB, Hjalmar Petris väg 49, S-352 46 Växjö, Sweden, Tel: +46 470-705200, Fax: +46 470-705201,

www.kraftpowercon.com

Dimensions........................... See diagram below

Dimensional draft operator panel

3.3.2 I/O module

Mounting ...........................On terminal rail or direct on vertical surface

Dimensions........................See diagram below

Dimensional draft I/O module

3.4 Conformity with standards

EN 60529........................... Class of enclosure IP20

EN 50178...........................LVD. Electronic equipment, including power electronics in electrical

power installations.

EMC standards ...................Tested in a system context, not as individual product. See relevant

system manual.

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